Corrugated packaging material



March 14, 1961 c. A. FOURNESS CORRUGATED PACKAGING MATERIAL 4 Sheets-Sheet 1 Filed June 25, 1957 1 N VEN TOR. fkmleaaibzerrzeg March 14, 1961 c. A. FOURNESS CORRUGATED PACKAGING MATERIAL 4 Sheets-Sheet 2 Filed June 25, 1957 INVENTOR. C/zczrlaa fl/6u/vze66,

BY @W, WW

March 14, 1961 c. A. FOURNESS 2,974,716

CORRUGATED PACKAGING MATERIAL Filed June 25, 1957 4 Sheets-Sheet 3 INVENTOR.

h -mazes sectibiialvi'ew aken along the :line 2+2 1 I 'CQRRUGA'I ED PACKAGING MATERIAL .Charles Albert Fourness, Appleton, Wis, assignor to Kimberly-Clark Corporation, Neenah, Wis, a corporation of Delaware I v f" i FiledJune Z5, 1957,15? -N0. 667,852

' 1 10 Claims. 01.1 5441 Thisinvention pertains to a corrngated'laminatedpaper and the apparatus for making :such a paper, and in particular to a corrugated laminated paper that is universally fi'eiriblninalldi'rections; "l i. 1 1. In a corrugated .laminated'ipaper it desirable that the paper... be universally flexible, instill-directions. This is particularly true when the paper is to be used for wrapping bi" as aflpackagingmaterial so it will readily assume the shape of'theobjectornnaterial being wrapped.

a: C:orrugated papers. of various designs and, patterns are-disclosed the prior art; however, none of these priorgartpapefr's havethegcharacteristic of being universally flexible as contrasted te-those which resist folding in adirec'tion transverse to. the corrugations. The closest any-of the; prior art comes "tosolving this problem 'is where, thepaper is flexible intwo directions, generally in the transverse and longitudinal directions. 0 i

wfiitwthe same timejit, is necessary that the paper have V sulficient cushioning power which-depends upon the thick nessandot-herstructural characteristics or cushioning as it will; be generally called; hereinafter, to protect the rugated laminated paper that is universally/flexible in alldirectionsq I H v "Another o jeet of the invention is to provide a cor rugate'd laniinatedapaper that is universally flexible and has ;.good cushioning =characteristics.

; -;A .stillp furtherj objectcf the inventionis-to provide a corrugated laminated paper that is simple and econor'ni A -sti'll further object of the invention is'to provide an 7 cal to manufacture. I

ap "aratusiofnovel constructionfor making a' corrugated laminated paper inoneoperation. r Y V :Astillgfurthet object of the invention is to provide acormgated laminated .paper which has a large variety Conses of uses and which may be tailored to. suit the .spe'cificus'e. a

Further objects; of the'invention. will .be apparent'upon lopment Of j the specification "with reference. to h 1;; "In the drawings 1 J 65. Figure; .11 shows-a planviewcf thecorrugated laminated H paper;enrbodyingitheinvention 1: I

2,974,716 Patented Mar. 14, 1961 ICC - 2 and apparatus in which a corrugated laminated paper is made.

Figure 5 is a side view in elevation of the apparatus embodying the invention.

' Figure 6 is a plan view in elevation of the apparatus shown in Figure 5.

Figure 7 is a sectional view taken along the line 7--7 in Figure 6.

Figure 8 is a sectional view taken along the line 8-8 in Figure 6; and

Figure 9 is a sectional view taken along the line 9-9 in Figure 6.

Referring now to Figures 1 and 2, there is shown a corrugated laminated paper embodying the invention generally denoted by the numeral 10. The paper is comprised of a corrugated ply 11 and a substantially fiat backing ply 12; The corrugated, ply 11 is provided with a plurality of short, transverse, regularly spaced corrugationsltwhich'are arranged'in the alternating rows 15 'asjbest-shoWn in Figure. 11. Defining the corrugations on their sidesand at their ends are the flat unnaised portions .16. i In other Words, the ends of each corrugation terminate in the unrai'se'd or flat portions 16 in the rows 15 vadjacent thereto. The ends of each corrugation lie. between the'ends of two corrugations in the adjacent rows in a substantially contiguous relationship. 7 In thepreferred embodimentthe ends'of the corrugations 14 in one row appear to slightly overlap the ends of the corrugations 14 in the adjacent rowsdue to the transition 17 between the corrugated and noncorrugated areas. The ends of corrugations 14in adjacent rows are interconnected with the ends of corrugations in adjacent rows 1 bythe longitudinal corrugations 13, as best shown in Figure l, p In other'words, ply could be characterized by both transverse and longitudinal corrugations. a Referring now to Figure 2, it can be seen that the backing ply 12 is secured to the underside of the flat portions 16 by some suitable adhesive. One adhesive or glue that is particularly adapted for this use is the air drying type, although other types, such as thermal setting and pressure sensitive types, may be used in the practice of the invention; The adhesive may be appliedto the entire surface of the backing ply or it may be selectively touching relationship. e V The length of the corrugations 14 in the transverse direction is approximately the same as that of the flat portions 16 as best shown in Figure 2. In the longitudinal direction the width of the corrugations 14 is somewhat .lessthan that of the flat portions 16, as shown in Figure 3. However, these dimensions are merely a matter of choice {and may be varied to meet the specific needs. The type ,ofpaper-thatisto be used for each of'the plies is also ,a matter of choice depending upon the structural cha r acteristics required.

. Referring back to Figure l, itcan now be seen that the corrugated. laminated paper as constructed is universally fiexible. If "it should hey-desired to fold thepaper along a transverse line, the corrugations '14 will form a natural, line of fold. On the other hand, if it .shouldbe "desired to fold the paper along a longitudinal line, a longitu dina1 corrugation 1-8 wiiltorm a natural line of fold. Still' further, if it should be desired to fold the paper along a ,diagonaldirection, itcan be'seen that the corrugations 14 and particularly the transitions 17 'forma natural lineof fold in this direction. Thusthe paper will readily assume the shapeof the objectwrapped therein so as topresent' a neat and well cushioned package. 7 I

A method used for making the laminated paper pr'e- I wiously described can best be understood by referring to Figure- 4'. The paper for the ooirugated ply 11 issttir edi on therolliltl'which may be -positioned inany convenient applied in only those areas of the two plies which are in 3 location. The paper then is pulled from the roll 19 into the gathering rolls 21 which draw together the paper transversely to provide sufficient surface area to form the longitudinal corrugations 18 as will be apparent later on. After leaving the rolls 21, the paper is then drawn into the forming rolls 22 which by means of a complementary teeth and indentation arrangement form the corrugations that have been previously described. In the meantime, the backing ply 12 is drawn from the roll 23 over the idle roll 24 onto the glue roll 25. At this point the glue or adhesive is applied to the backing ply either in a selective pattern or over the entire surface. The paper then passes over a second idle roll 26 onto the roll 27 which co-operates with the lowermost of the forming rolls 22 to bring the two plies together. As shown in Figure 4, the amount of time the glue or adhesive is exposed to the air for purposes of partial setting is determined by the distance between the roll 26 and the roll 27. After the laminated paper leaves the forming rolls, it is then wound onto the roll 60 in which form it may be stored until needed.

In Figures and 6 a more detailed illustration of the apparatus is shown. The roll 19, on which the paper for making the corrugated ply is stored, is rotatably mounted on the upright supports 28. The supports 28 are secured by any suitable means to a horizontal frame member 29.

As shown in the drawing, three pairs of gathering rolls 21 are mounted on the frame member 29. The number of pairs that are needed depends upon the type of paper that is being used to form the corrugated layer and the amount that the paper is to be gathered. After the gathering operation the corrugated ply is of the same width as the backing ply, as will be apparent later on. It should be noted that the gathering could be accomplished by other means than the previously described rolls.

The top roll 30 of each pair of gathering rolls is provided with a plurality of regularly spaced annular flanges 31 as best shown in Figures 7 and 9. These flanges 31 co-operate with complementary annular grooves 32 in the bottom roll of each pair. The depth of the flanges 31 is increased and the regular spacing is decreased in each succeeding pair of rolls. Similarly the depth of the grooves is increased and the width and the regular spacing is decreased in each succeeding pair of rolls. As is best shown in Figure 6, the paper as it progresses through the gathering rolls is gradually reduced in Width by the formation of the longitudinal creases by the co-operation of the flanges 31 with the grooves 32. After the paper has passed through the gathering rolls, it is then ready to be formed into the corrugated pattern previously described.

As shown in Figure 7, the forming rolls 22 are comprised of an upper roll 33 and a lower roll 34 rotatably mounted on the frame 35. As shownin Figure 5 the upper and lower rolls are interconnected by the gears 36 and 37. In this manner the two rolls may be driven simultaneously by a single drive means (not shown). It should also be pointed out that the top roll 30 of the pair of gathering rolls adjacent to the forming rolls is driven by a chain drive 38. as shown in Figure 6. The top roll 30 in turn drives the bottom roll '32 by the gears '38a.' The remaining gathering rolls are in turn driven by subsequent chain drives 38 and gears 38a. Inthis manner, all of the rolls that are used in the apparatus,

4 Each disk is secured to a shaft 42 by the keyway 43 in order that rotation may be imparted thereto, as shown in Figure 7. I

The disks of the top forming roll are provided with an alternating series of teeth 44 and indentations 45. In the first disk 39 the keyway 43 lies along the center line bisecting diametrically opposite teeth 44. In the adjacent disk 40 the keyway is offset from the center line so that the indentations 45 are aligned with the teeth 44 of the 1 adjacent disks 39 when the disks are mounted in alternate order on the shaft 42.

The lower forming roll 34 is comprised of similarly constructed disks which are complementary to those on the upper roll. In other words, the indentations 47 of the disk 46 receive the teeth 44 and vice versa, the indentations 45 receive the teeth 48. It can now be seen that this alternating on-center-keyway, ofi-center-keyway arrangement of the forming disk on the shaft results in rolls which form the corrugated pattern shown in Figure 1.

Adjacent the lower roll 34 is a plurality of rotatably mounted guide members 49. The forward face 50 of the guide members 49 is provided with a radius of curvature complementary to that of the lower roll 34. This face rests in the annular groove 41 between the disks 46 and serves to hold the paper on the forming roll in its corrugated form until it can be secured to the backing ply. It should be pointed out that the guide members roll 33 is comprised of a plurality of alternating disks forming rollscould be constructed in an i n te grated fashion, the preferred embodiment of the :inventioncontemplates the separable disk assembly previously described.

49 ride in the previously formed areas which eventually become the longitudinal corrugations 18.

Referring back to Figure 5, the paper for the backing ply 12 is stored on the roll 23 mounted on the supports 52. The paper moves from the roll 23 to an idle roll 53 which is mounted on the frame member 54. The paper then moves to the adhesive or glue roll 55, part of which is immersed in the reservoir 56. A doctor knife 57 or any other suitable means may be used for removing excess glue from the roll 55. This roll may have a smooth outer face or it may have an intaglio design, in order to selectively print the glue on the paper. If the latter procedure is followed, a considerable saving in glue will be realized and at the same time the flexible properties of the corrugated paper will be enhanced to some extent. After the paper leaves the glue roll 55, it then passes over a second idle roll 58 which serves to position the paper for the next operation. The paper then passes to the roll 59 which co-operates with a lower forming roll 36 to secure the corrugated layer and the backing layers together. As was mentioned previously, the distance between the idle roll 58 and the roll 59 depends upon the amount of time necessary to partially set the blue on the face of the backing layer. In other words, this distance can be varied in order to suit the needs of the specific adhesive or glue that is used. Although air setting type adhesive has been mentioned as particularly adapted for this use, it is contemplated that other types such as heat setting adhesive may be used. In that case it may be necessary to heat one or more of the rollers, particularly roll 59. As the papers pass between the roll 59 and the lower forming roll 36, the backing ply 12 is forced against the flat portions 16 of the cormgated ply 11. It the glue has had sufficient time to set. then the two plies will be secured together in the manner shown in Figure 1.

. The paper then goes onto a storage roll 60 which is mounted on the supportsfil. As was mentioned previously, the rolls 55 and 59 as well as the gathering and forming rolls are driven by suitable means depending fromthe' lower forming roll 36. In this manner, all of the rolls can be synchronized, which will provide a smooth continuous operation. This is particularly important where an intaglio glue roll 55 is used for it is necessary that the glue patte'rnconform and be.- aligned with the pattern of the flat portions of the backing ply 12.

As was nientioned previously, numerous types of paper may be used for both the corrugated ply 11 and the backing plyJIZ. This is a matter; of choice which depends upon 'thestructifi'al characteristics 'ref'q'uired inthe, final product- I f It is also coritempla'tedthat a 'compoundlaininated structure 'could'be'used Within th'efis'cope of the invention. Although certain d'e't'a'il'shave been specified in the description of the invention, it is to be understood that this is merelyby way of example rather than limitation.

It is contemplated that certain modifications of the invention may be made within the scope of the claims without departing from the spirit of the invention.

I claim:

1. An apparatus for making corrugated laminated paper comprising at least one pair of rolls for gathering a first ply of said paper, each of said pair of gathering rolls having one roll provided with a plurality of spaced annular flanges, and a second roll provided with spaced annular grooves complementary with said flanges, a pair of forming rolls for corrugating said first ply, said forming rolls comprising a plurality of regularly spaced annular disks, each of said disks having a series of alternating teeth and indentations on its outer periphery, the disks of one of said forming rolls intermeshing with the disks of the other said forming roll, roll means for selectively coating an adhesive on a second ply of said paper, and

further roll means co-operating with one of said forming rolls for bringing said first and second plies in touching relationship whereby said first and second plies are secured together by said adhesive. 2. An apparatus for making corrugated laminated pa per comprising at least one pair of rolls for gathering a first ply of said paper, each of said pair'of gathering rolls having one roll provided with a plurality of spaced annular. flanges, and -,a second roll provided with a plurality of spaced annular grooves complementary to said flanges, a pair of forming rolls for corrugating said first rality ofspaeed annular grooves complementary to said flanges, a pair of forming rolls for corrugating said first selectively coating an adhesive on a second ply, and

further roll means co-operating with one of said forming rolls for bringing said first and second plies in touching relationship, guide means co-operating with said annular grooves, and means for simultaneously driving all of said rolls.

5. A laminated corrugated packaging material comprising a corrugated ply having rows of alternating raised and fiat portions, the ends of each of said raised portions being adjacent to a fiat portion in the adjacent rows and juxtaposed to the ends of the raised portions adjacent said last named flat portion, corrugations parallel with said rows vand intersecting the ends of said raised portions,

and a backing ply secured to the flat portions of said corrugated layer.

6. A laminated corrugated packaging material comprising a corrugated ply having rows of transverse alternating raised and flat portions, the ends of each of said raised portions being adjacent to a flat portion in the adjacent rows and juxtaposed to the ends of the raised portions adjacent said last named flat portion, said flat porply, each of said forming rolls comprising a plurality of regularly spaced annular discs separated by annular grooves, said disks having a series of teeth and indentations, alternate disks being indexed so that the teeth thereon are aligned with the indentations on adjacent disks, the teeth on the disks comprising one of said forming tlOllS intermeshing with the teeth on the disks comprising the other said forming roll, roll means for selectively coating an adhesive on a second ply, and further roll means co-operating with one of said forming rolls for bringing said first and second plies in touching relationship whereby said first and'second plies are secured together by said. adhesive.

3. An apparatus for makingflcorrugated laminated paper comprising atv least one pair of rolls for gathering a first ply of said paper, each of said pair of gathering rolls having one roll provided. with a plurality of spaced annular flanges, and a second roll provided with a plu rality of spaced annulargrooves complementary to said flanges, apair of forming rolls for corrugating said first ply, each of said forming rolls comprising a plurality of regularly spaced annular, disks separated by annular grooves," said disks having a series of teeth; and indentations, alternate disks being indexed so that the teeth there on are aligned with the indentations on adjacent disks, the teeth ,on the diskscomprising one of said forming rolls intermeshing with the teeth on the disks comprising the other said, forming roll, roll means for selectively coating an adhesive on a second ply, and further roll means co-operating 'withaone of said forming rolls for tions being substantially wider than said corrugations, corrugations parallel with said rows and intersecting the ends of said raised portions, a backing ply, and adhesive means for securing said backing ply to said flat portions.

7. A laminated packaging material comprising a corrugated ply having contiguous longitudinal rows of transverse alternating raised and flat portions, the ends of each of said raised portions abutting a flat portion in the adjacent rows, said ends being juxtaposed to the ends of the raised portions adjacent said last named flat portion, corrugations parallel with said rows and intersecting the ends of said raised portions, and a backing ply secured to the flat portions of said corrugated ply.

8. A laminated packaging material comprising a corrugated ply having a plurality of short transverse regularly spaced corrugations, each of said corrugations defined by fiat portions, the ends of each said corrugations juxtaposed to the ends of the longitudinally adjacent corrugations, a longitudinal corrugation intersecting the ends of longitudinally adjacent corrugations, and a second ply secured to the flat portions of said first ply.

9. A laminated packaging materialcomprising a corrugated ply having a plurality of short transverse regularly spaced corrugations arranged in longitudinal rows,

each of said corrugations definedby flat portions in the adjacent rows, said fiat portions being substantially wider than said corrugations, the ends of each said corrugations juxtaposed to the ends of the longitudinally adjacent corrugations in adjacent rows, a longitudinal corrugation intersecting the ends of longitudinally adjacent corrugations,:a second ply, and adhesive means for secur ing said second ply to said flat portions.

10. A laminated packaging material comprising a corrugated ply having a plurality of short transverse regularly spacedcorrugations arranged in longitudinal rows,

each of said corrugations defined by flat portions in the bringing said first and second plies in touching 'relationgrooves.

4. An" apparatus for making corrugated laminated pa per comprising at least one pair of rolls for gathering I jacent corrugations inadjacent rows, a longitudinal cor a first ply 'of said paper, each of said pair of gathering rolls'h'aving one roll provided with alplurality of spaced annular flanges and a second roll provided with a pluadjacent rows, said flat portions beingsubstantially wider than ,said corrugations, the ends 'of each of said corrugationsjuxtaposed tojthe ends of the longitudinally adrugation intersecting'theends of longitudinally adjacent corrugations, a substantially flat ply, and adhesive means for securing said second ply' to said flatportionsr (References on following page) i References Cited in the file of this patent UNITED STATES PATENTS Fletcher Sept. 2, 1884 Hahn July 18, 1911 5 Beran Aug. 17, 1915 Beran Apr. 3, 1923 Langston Sept. 20, 1927 Goettsch Aug. 18, 1936 Toohey et a1 Sept. 19, 1939 10 Ruegenberg Sept. 30, 1941 8 FOREIGN PATENTS Great Britain NOV. 28, 1889 Great Britain Apr. 10, 1922 Germany Sept. 11, 1933 France May 3, 1915 France June 14, 1921 

